6EY18ALW GenSet

Common issues

• Fuel injection nozzle fouling (exacerbated by HFO operation and low-load running)
• Exhaust valve seat wear and burning (common with HFO, poor combustion, or inadequate cooling)
• Turbocharger fouling on both compressor and turbine sides (especially from prolonged low-load operation with HFO)
• Lube oil degradation and contamination (due to HFO combustion byproducts, leading to increased wear)
• Cooling water system scaling or leaks (affecting heat transfer and potentially causing localized overheating)
• Fuel injection pump element wear (abrasives in HFO, poor fuel treatment, or cavitation)
• Main and crankpin bearing wear (often linked to lube oil quality, alignment, or excessive vibration)

Inspection checklist

• **Engine Exterior & Cleanliness**: Inspect for any visible leaks (fuel, lube oil, cooling water, exhaust gas). Check general cleanliness and integrity of insulation on hot surfaces.
• **Fuel System**: Verify fuel pressure and temperature (before/after filters). Check condition of fuel filters and high-pressure fuel line integrity. Listen for abnormal noises from fuel pumps.
• **Lube Oil System**: Check oil level, pressure, and temperature. Visually inspect oil for clarity and presence of water. Review recent lube oil analysis reports for trends.
• **Cooling System**: Check cooling water levels in expansion tank, system pressure, and temperatures (inlet/outlet). Inspect for leaks and signs of scaling or corrosion.
• **Exhaust System & Turbocharger**: Monitor exhaust gas temperatures per cylinder and before/after turbine. Listen for abnormal turbocharger bearing noise/vibration. Visually check for exhaust leaks and turbocharger cleanliness (if accessible).
• **Valve Train**: Listen for abnormal noises (e.g., excessive tappet clearance). If scheduled or suspected, check valve clearances.
• **Generator & Controls**: Check generator bearing temperatures, winding insulation (visual), and functionality of the control panel, alarms, and safety shutdowns.
• **Vibration & Noise**: Perform a general assessment of engine vibration and noise levels during operation. Note any unusual patterns.

Service intervals

Typical wear limits

Ranges are typical for this design class. Always confirm against the manufacturer documentation for your serial number.

Critical spares

• Fuel injection nozzles/elements (complete set or at least 2-3 per cylinder)
• Exhaust valve spindles and seats (at least 1-2 per cylinder, or complete cylinder head if policy)
• Full set of fuel filters (primary, secondary, fine)
• Full set of lube oil filters
• Turbocharger bearing cartridge/repair kit
• Assorted gaskets and O-rings (cylinder head, fuel pump, common flanges)
• Start air valve complete or repair kit
• Common pressure and temperature sensors

Safety

• **High-Pressure Fuel Leaks**: Risk of fire and severe injury from atomized fuel spray. Always check for leaks, especially from high-pressure lines and connections.
• **Hot Surfaces**: Exhaust manifold, turbocharger, cylinder heads. Risk of severe burns. Ensure insulation is intact and guards are in place.
• **Rotating Machinery**: Flywheel, coupling, and any exposed rotating parts. Ensure all safety guards are correctly fitted and secured.
• **Electrical Hazards**: Generator terminals, control panels, and associated wiring. Ensure proper lockout/tagout procedures are followed during any electrical work.
• **Noise Levels**: Prolonged exposure to engine room noise without appropriate hearing protection can cause permanent hearing damage.

Class survey

A class surveyor typically focuses on: 1. **Safety Devices Functionality**: Verification of overspeed trip, low lube oil pressure shutdown, high cooling water temperature shutdown, and emergency stop functionality. 2. **Engine Room Condition**: Cleanliness, absence of oil/fuel leaks, integrity of fire insulation, proper functioning of fire detection and extinguishing systems. 3. **Load Test**: Ability of the genset to take and maintain rated load, stability of frequency and voltage, and absence of excessive smoke. 4. **Exhaust System Integrity**: Inspection for leaks, cracks, proper lagging, and condition of expansion bellows. 5. **Fuel and Lube Oil Systems**: Integrity of piping, filters, heaters, purifiers. Review of recent oil analysis reports and fuel treatment logs. 6. **Cooling System**: Inspection for leaks, proper temperatures, and condition of heat exchangers. 7. **Maintenance Records**: Review of planned maintenance system (PMS) records, defect reports, and spare parts consumption logs. 8. **Vibration and Noise**: General assessment during operation, noting any unusual levels or patterns.